Making a 1/4" X 1/2" X 5" slot in solid G10?

Robert Hankins

Robert Hankins

Joined
May 19, 2003
Messages
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Once again I rely on your expertise...
Seems like a straight forward question but here goes.
Need to make a 1/4" X 1/2" hole thru the center of a solid piece of G10 that is 1 1/8" X 1 1/2" X 5" long. Making some fighters with a 1/2" wide tang thru handle that will have a integral 1/4" X 20 threaded end for a screw on pommel.

Using a drill press what is the most efficient way of doing this?
What is the best type of bit?

Have been drilling two 1/4" holes half way thru and trying to meet in the middle. Using one of the drill bit reamers to clean out the middle.
Need a faster easier way of doing this:D
 
I say to cut the block in half lengthwise and dado with a milling machine the two halves and glue them back together. You could always pin the two halves together also if you are worried about the glue joint being weak.
 
Does anyone sell handles with the slot already milled in them? I would like to find some made of canvas micarta, curly maple or black walnut :D
 
I have often wondered why we dont use the square mortise and tenon drills on wood handles,might even work on fiber handles.If you dont know what I am talking about,look in the wood working supply catalogs or on line,they are a square chisel with a drill bit inside them to use in the drill press.Leaves a nice clean square hole and could be run side by side with holes.

just a idea.
Bruce
 
Bruce
Would if I had a mill:D
Bruce E. that may work as I plan on using Canvas Micarta as well. Easier to drill than G10 especially a 5" deep hole.
Already square is a good thing!
 
Terry thats it,I thought you could get a setup for the drill press though.But that isnt that expensive as it is.

Wonder if it would work for hidden tang handles.
Bruce
 
The mortise machine is a good choice but not if your dealing with curved handles, like antler. I put a palm swell in JUST ABOUT every handle I make anymore so that means bending the tang to acommodate the curvature, therefore a curved hole so it leaves plenty of room away from the hole when shaping. It's a real PITA when you get everything in place, let it set and cure and then come back and sand though the handle into the inner hole because you had to make it big for the curved tang. :(

What I do is, lay the handle material up tight against the guard/bolster, figure out the angle I need to cut the block end to leave the most space from both sides from the center of the block. After I cut the block end,lay the block up against the guard and mark the tang, drill in from both ends angling the block so the drill bit follows the flow of the tang marking. Next I take a dremil with a spiral cutter, I took a 1/8" piece of plain round stock and welded it to the spiral bit to give it the needed added length to get well past the center of the block, start out with a short spiral cutter bit for the first inch or so and then put in the longer modified bit, if you don't go crazy you can end up with a really clean curved hole that fits the tang real nice, I always over size the hole just enough to allow the glue to run and fill all the inside voids. After a few handles you can work a hole though a block in a short amount of time. Also always leave the hole marking you made on the out side of the block to use as a reference so you don't grind to deep. Easy as pie. ;)

Hope this helps

Bill
 
Great advice Bill will give it a try.
Thanks Mr Bump but I wouldn't feel right asking you to do twenty or so handles for me:D
 
a guy at work had one of the Harbor Freight machines and let me borrow it. I have now made 1/4" wide by 1/2" long rectangular holes in a couple pieces of curly maple. :D The 1/4" bit i used only went 2" deep so i had to cut the pieces to 4". Can i use these pieces of wood with 3/16" thick blades or is the slot too wide (I would use epoxy to fill the space and use a screw on end cap to hold it all together)?
 
You can get Mortising attachments for your drill press as well. I've even seen them at the big box stores, but any decent woodworking store or online store will probably have them as well.

I'd agree that the milling machine is the way to go too, I've used one for making slots like this for some woodworking tools, but I haven't personally picked one up yet soooooooo :o

Jon
 
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